Energy system for electric vehicle

ABSTRACT

An energy providing system for an electric vehicle is described. The system includes a rotor mounted on a generator. A rechargeable or replaceable battery provides electric energy to a starter motor which initiates rotation of the rotor. The rotor is coupled to a generator which supplies electric energy to a motor that powers the vehicle drive train. The system is attached to the interior of the vehicle body and is maintained in a substantially horizontal position even when the vehicle travels over uneven surfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of U.S. applicationSer. No. 09/890,474, filed Aug. 1, 2001, which is a national stage ofInternational Application No. PCT/US01/03366, filed Feb. 1, 2001, whichclaims the benefit of U.S. Provisional Patent Application Serial No.60/179,944, filed Feb. 3, 2000.

FIELD OF INVENTION

[0002] The present invention relates generally to electric vehicles andenergy or energy systems for such vehicles. More specifically, thepresent invention relates to a system for providing energy to thevehicle in a way that preserves and extends the life of the battery.Finally, the present invention relates to an electric vehicle and to theplacement of the energy system, such as a generator and associatedcomponents within the electric vehicle.

BACKGROUND OF THE INVENTION

[0003] Concerns about air pollution emitted by gasoline poweredautomobiles, the cost of fuel, and noise pollution have led to a greatinterest in the area of alternative means for powering vehicles such asautomobiles. Of particular interest are vehicles that are powered inwhole or in part by electrical energy. These vehicles are typicallypowered by the electrical energy provided by a battery.

[0004] One of the drawbacks of electrically powered vehicles, however,is the capacity of the batteries to adequately power the vehicles. Thefrequent need to recharge batteries and/or replace batteries has madethe development and manufacture of electrically powered vehiclescommercially non-viable.

[0005] Accordingly, it would be desirable to provide an electric vehiclethat can travel relatively longer distances with less frequentreplacement and/or recharging of the batteries. Moreover, it would bedesirable to provide an electric vehicle wherein the life of thebatteries can be preserved.

SUMMARY OF THE INVENTION

[0006] The present invention addresses all of the above-describedproblems with the existing electrical vehicles.

[0007] In one aspect, the present invention is directed to an energysystem for an electric vehicle that includes a generator for providingelectrical energy, a rotor coupled to the generator and a starter motorfor initiating rotation of the rotor. The rotor is rotatably mounted onthe generator.

[0008] In another aspect, the rotor includes mobile weights housedwithin cavities of the rotor. In another aspect of the presentinvention, at least the generator and rotor may be attached to theinterior body of the car. The rotor and generator remain stable and in asubstantially horizontal position, even when the vehicle travels overuneven surfaces.

[0009] Thus, in another aspect, the present invention is directed to anenergy providing system that includes means for maintaining the rotorand generator in a substantially horizontal position. In one aspect, themeans for maintaining the rotor and generator in a stable, substantiallyhorizontal position includes a double bearing assembly attached to theinterior of the vehicle body and to a framework attached to thegenerator.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a side view of an electrical vehicle embodying an energysystem of the present invention in association with other components;

[0011]FIG. 2 is a front view of an electrical vehicle embodying theenergy system of the present invention;

[0012]FIG. 3 is a perspective view of the energy system of the presentinvention;

[0013]FIG. 3A is a partial, enlarged view of the energy system of thepresent invention;

[0014]FIG. 4 is a cross-sectional view of the top portion of the rotorof the energy system of the present invention;

[0015]FIG. 5 is a plan view from the bottom of the top portion of therotor of the present invention;

[0016]FIG. 6 is a plan view of the bottom portion or base plate of therotor of the present invention.

[0017]FIG. 7A is a front view of a mobile weight used with the rotor ofthe present invention;

[0018]FIG. 7B is a side view of the moving weight of FIG. 7A;

[0019]FIG. 8 is a partial, cross-sectional view of the double bearingassembly of the energy system of the present invention; and

[0020]FIG. 9 is a partial, cross-sectional view of the columnar memberof the energy system of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0021] Turning now to the figures, FIG. 1 shows a vehicle 10 includingthe energy system of the present invention. As shown in FIG. 1, vehicle10 includes the energy system 12, preferably located in the front of thevehicle. The energy system 12 is electrically coupled to a motor 14,which powers the drive train 21 of the vehicle. Battery 16 may belocated near the rear of the vehicle and provides electric energy to thestarter motor 18 of the system 12.

[0022] Battery 16 provides electric energy to a starter motor 18 whichis coupled to generator 20 and initiates rotation of rotor (flywheel) 22which is coupled to the rotating shaft of generator 20. Generator 20powers motor 14, which in turn is coupled to the drive train 21 andaxles of the vehicle. During operation, the motor will eventually slowin response to the load of the vehicle, the wind resistance, and theresistance from the road, etc., and requires energy from generator 20. Atachometer or other comparable monitoring device (not shown) monitorsthe rotation. When the rotation or energy falls to a predeterminedlevel, the battery 16, which is linked to starter motor 18, will beprompted to provide electric energy to starter motor 18, and repeat theabove process. Although the operation of the battery 16 is not constant,the periodic operation of the battery will require recharging orreplacement of battery 16. However, because battery 16 is only requiredto provide the initial electric energy to the starter motor, the life ofthe battery can be prolonged.

[0023] As shown in FIGS. 1 and 2, the energy system 12 is typicallylocated within the body of the vehicle where, in a gasoline poweredvehicle, the internal combustion engine would have been. System 12 mayinclude, in general, a generator 20 and a rotor 22 rotatably mounted togenerator 20 via wrapping flange or sleeve 19. A starter motor 18 mayalso be located near the rotor 22. It is preferred that starter motor 18be placed in a horizontal position and that the entire cluster of rotor,generator, starter motor be balanced. The generator, rotor andelectrical starter motor 18 are attached to the body interior 24 of thevehicle 10 by a framework 26, as shown generally in FIG. 2. The centerof gravity of the cluster of the generator 20, rotor 22 and motor shouldbe lower than the horizontal line of the arms 28 and 30 of thesupporting framework. The arms 28 and 30 of the framework 26 areattached to one end of the double bearing assembly 34, shown generallyin FIG. 2, and in more detail in FIG. 8. The other end of the doublebearing assembly is attached to a moveable shaft 38. As described inmore detail below, shaft 38 is attached to and moveable within acolumnar member 42. Member 42 is, in turn, attached to the interior ofvehicle body 24.

[0024] A more detailed view of the energy system 12 of the presentinvention is shown in FIG. 3. As shown in FIG. 3, generator 20 may beattached by resilient mount 21 to the floor of vehicle 10. Rotor 22 isrotatably mounted on the generator 18. Rotor 22 is attached to theinterior rotating portion of generator 20. Rotation or rotor 22 therebycauses rotation of the interior components (shaft) of generator 20 toproduce electric energy, as will be understood by those of skill in theart.

[0025] Starter motor 18 may also be coupled to rotor 22 by wrappingflange or sleeve 19. Starter motor 18 provides the impulse energy toinitiate rotation of rotor 22. The initial electric energy may beprovided to starter motor 18 by battery 16, as previously described andshown in FIG. 1.

[0026] The principal part of the rotor 22 is shown in FIGS. 3A and 4. Asshown in FIG. 4, rotor 22 (or flywheel) includes a top portion 46 and asecond bottom portion or base plate 50. The top and bottom portions 46and 50 may be attached by any known means, such as bolts or screws. Topportion 46 of rotor 22 includes a depending lip 47, as shown in FIG. 4,and is relieved to receive bottom plate 50. Accordingly, when the twoportions of rotor are brought together, the peripheral portion of baseplate 50 is attached to depending lip 47 and the interior portion of thebase plate is fitted into and attached to relieved portion 48 of rotortop portion 46. When brought together, the two portions provide gaps orraceways 60 to facilitate movement of mobile weights 64, as described inmore detail below. It is preferred that the surfaces of the top andbottom portions that define raceways 60 have a minimal roughness and,more preferably, that they be polished.

[0027] The rotor may be made of iron, steel or any other suitable metal.The diameter “d” will depend on the diameter of the generator and thedepth “h” will depend upon the length of the generator. Preferably,depth “h” is approximately □ of the length of the generator. Thediameter “D” may be any size, but will depend, in part, on the size ofthe vehicle.

[0028] Top portion 46 and bottom portion 50 also define slots orcavities in the rotor. As shown in FIGS. 5 and 6, cavities are radiallyspaced on rotor 22 (like spokes on a wheel). In the preferredembodiment, the rotor may include six (6) generally rectangular cavities49 to receive the mobile weights. Of course, rotor 22 may have more orfewer cavities, as desired, provided that the cavities are uniformlyspaced on the rotor to maintain balance. To provide for perfect levelingof the cavities, the cavities are made with the top and bottom portionsof the rotor attached. It is preferred that the cavities be polished.

[0029] As shown in FIGS. 7A and 7B, mobile weights (which may be made ofsteel or other metal) are substantially rectangular. The width 64 a ofthe moveable weights 64 is essentially equal to the width of thecavities 49. When the gear is at rest, the weight is at a minimumdistance from the center of rotation. This will provide a minimal orsmall starting load for the starter motor 18. As rotor 22 begins to spinand the mobile weights move radially outwardly toward the outerperiphery of the rotor, it turns the shaft of generator 20 whichsupplies energy to motor 14.

[0030] At the time of assembly of rotor 22, weights 64 are placed incavities 49. In one embodiment, the weights may include slides 67 tofacilitate movement of the mobile weights within the cavities. Thesurfaces 67 a of slides 67 may, optionally, be treated or covered withplastic or other material. When the top and bottom portions of rotor 22are brought together, slides 67 of mobile weights are located within thegap or raceway 60 formed by the portions of the rotor. In anotherembodiment, weights 64 may include rollers instead of slides. It ispreferred that the sides 69 of the weights 64, which contact the sidesof the cavities 49, be polished.

[0031] Also, as shown in FIG. 4, raceway 60 may be slightly angled. In apreferred embodiment, the difference in the raceway width at the centralportion of the rotor and the more peripheral portion is on the order ofapproximately 3°. The slight angle facilitates return of the mobileweights to their starting positions (i.e., near the center of rotation).

[0032] The double ball bearing assembly 34 is shown in FIG. 8 in partialcross-section. The assembly includes a left portion 63, and the otherhas a right portion 65. The two portions of the assembly are joined by aconnecting piece 66. The length of connecting piece 65 may be varied toimprove the ability of the system to compensate for movement of thevehicle over uneven surfaces. This assembly also allows for easierservicing and adjustments.

[0033] One end of the double bearing assembly 34 is attached to columnarmember 42, and more specifically to shaft 38 disposed within columnarmember 42. Shaft 38 is fitted with spring 74 to allow for limitedside-to-side movement of shaft 38 and, consequently, double bearingassembly 34. Spherical bearing 78 also allows for limited vertical (upand down) movement of shaft 38. Spherical bearings may be made of steel,plastic or any other suitable material, as will be appreciated by thoseof skill in the art.

[0034] The outer columnar member 42 is attached at flange 82 to theinterior of vehicle body 10, as shown in FIG. 2. The combination ofdouble bearing assembly 34 and moveable shaft 38 allows for limited upand down, side-to-side and angular movement of the assembly, as shown bythe directional arrows in FIG. 3. Thus, when vehicle 10 moves overuneven or graded surfaces, this combination compensates for any changesin surface contour while maintaining the generator and rotor in asubstantially horizontal position. This also maintains stability of thevehicle 10.

[0035] The shaft 9 for attachment to the vehicle body is shown in FIG.9. As shown in FIG. 9, the shaft has the ability to move horizontally,whereby the spring recoils to its initial position. Also, shaft 38 maymove in a limited vertical position, allowing the angle to change. Thebody of the columnar member 42 is attached to the automobile body. Thenut 90 keeps the spring in place and an end ring 94 holds the bearing78.

[0036] In a preferred embodiment, spare car batteries may be maintainedin a cassette used in the free space which would have held the fueltank, as well as part of the trunk area. The assembled cassettes may bestored therein. The cassette may be removable. Service stations willhave spare cassette storage, as well as a charging station.

[0037] The present invention has been described in connection with itspreferred embodiments. It will be understood that the present inventionmay also be embodied in other forms without departing from the spirit orcharacteristics of the invention. The above description is intended tobe illustrative and non-restrictive, and the invention is not limited tothe above-description, but is set forth in the appended claims.

What is claimed:
 1. An electric vehicle comprising: a replaceable orrechargeable battery for providing electric energy to a starter motor; astarter motor coupled to a rotor for initiating rotation of said rotor;a rotor coupled to the shaft of a generator; and a generator forproviding energy to a motor.
 2. The system of claim 1 wherein said rotoris rotatably mounted on said generator.
 3. The system of claim 1 whereinsaid rotor comprises a first portion and a second portion mountedthereon, said first and second portions defining multiple cavities insaid rotor.
 4. The system of claim 3 wherein said cavities are radiallydisposed about the center of said rotor.
 5. The electric vehicle ofclaim 4 wherein said rotor comprises six cavities.
 6. The system ofclaim 4 further comprising mobile weights housed within said cavities.7. The system of claim 6 wherein said weights are adapted for movementfrom a radially inward position within said cavity to a radially outwardposition of said cavity.
 8. The system of claim 7 wherein said weightsinclude rollers to allow for movement within said cavity.
 9. The systemof claim 1 comprising a vehicle having a body with an exterior and aninterior wherein said generator, rotor and starter motor are attached tosaid interior of said body.
 10. The system of claim 9 further comprisinga supporting framework, said framework providing attachment of saidrotor, said generator and said starter motor to said body interior. 11.The system of claim 10 comprising means for maintaining said rotor in asubstantially horizontal position relative to changes in the angle ofthe vehicle body.
 12. The system of claim 11 wherein said maintainingmeans comprises a double bearing assembly attached to said framework.13. A rotor and generator assembly for use in an electric vehicle, saidrotor comprising: a top portion and a base plate attached to said topportion, each of said top portion and said base plate including aplurality of uniformly spaced cavities disposed about the center thereofand defining a plurality of raceways; a plurality of mobile weightswithin said raceways, said weights adapted for movement within saidcavities; and said rotor and generator being held by a frameworkattached to the body of the vehicle, said framework comprising first andsecond double-bearing assemblies.
 14. The system of claim 13 whereinsaid framework is attached to said vehicle by a pair of columnarmembers, each of said columnar members defining a central bore andmovable shaft within said bore, wherein said shaft is capable ofhorizontal movement.
 15. The system of claim 14 wherein said shaft iscoupled to a spherical bearing.
 16. The system of claim 14 wherein oneend of said shaft is attached to one of said double-bearing assemblies.17. The system of claim 13 wherein said mobile weight includes a pair ofslides for facilitating movement of said weights within said raceway.18. The system of claim 13 wherein said raceway is inclined between saidcentral and peripheral regions of said rotor to facilitate movement ofsaid mobile weights toward said central region of said rotor.
 19. Thesystem of claim 18 wherein said raceway at said radially outwardperipheral end of said rotor is upwardly inclined by approximately 3°relative to said raceway the radially inward end of said rotor.